EP2643275A1

EP2643275A1 - Novel cement that is resistant to internal sulphate reactions and to external sulphate attacks

Info

Publication number: EP2643275A1
Application number: EP11802504.8A
Authority: EP
Inventors: Michel Pasquier; Laetitia Bessette; François HUE
Original assignee: Vicat SA
Current assignee: Vicat SA
Priority date: 2010-11-25
Filing date: 2011-11-24
Publication date: 2013-10-02
Anticipated expiration: 2031-11-24
Also published as: US20140137772A1; FR2967999A1; US9034099B2; CA2815799C; CA2815799A1; EP2643275B1; WO2012069763A1

Abstract

A subject of the present invention is a novel cement that enables the preparation of concrete, grout or mortar that is resistant to internal sulphate reactions and to external sulphate attacks, and also the use of this cement for the preparation of concrete, grout or mortar.

Description

NEW CEMENT RESISTANT TO SULPHIC REACTIONS S

INTERNAL AND EXTERNAL SULFATIC ATTACKS

The present invention relates to a new cement for the preparation of concrete, grout or mortar resistant to internal sulfatic reactions and external sulphate attacks.

Concrete is a composite building material made from natural aggregates (sand, chippings) or artificial aggregates (light aggregates) agglomerated by a binder, usually a cement.

Concrete is commonly used for the construction of civil engineering works, buildings and for the manufacture of prefabricated elements. These structures require a concrete made with a cement which guarantees specific technical and mechanical characteristics, in particular with regard to setting time and resistance to short and long term.

The presence of a certain amount of sulphate ($) and tricalcium aluminate (C ₃ A) in the cement used for the concrete is described in the literature as necessary to maintain these technical and mechanical characteristics. Thus, the LE A 's Chemistry of Cement and Concrete (4th edition), published by PC Hewlett, p.272-273, teaches that too small a quantity of sulphate causes a catch too fast (catch "flash") harmful to the quality and strength of concrete in the short or long term. On the other hand, it is also taught that a too small amount (or the absence) of C ₃ A leads to the appearance of "false decision", that is to say of an abnormal and premature stiffening of the cement, a few minutes after contact with the water.

Ettringite is a mineral species composed of calcium sulphate and aluminum hydrate, with the chemical formula Ca ₆ Al ₂ (SO ₄ ) ₃ (OH) 12.2H ₂ 0. Ettringite is a product of the reaction between l C ₃ A tricalcium aluminate, sulfate and water. Ettringite can form during the setting of the concrete: it is called primary ettringite. The formation of primary ettringite favors the setting of the concrete and does not present any danger for the durability of this one. However, sometimes ettringite does not form during the setting of concrete but after it. Thus, when the temperature of the concrete is high (above 60 ° C) at the time of setting, for example due to the exothermicity of the reaction, the primary ettringite is formed then redissolved or does not form. All the reagents necessary for the formation of ettringite (C ₃ A, $, water) nevertheless remain present in the solidified concrete. After returning to room temperature and in a suitable environment, ettringite can then precipitate in the form of crystals in the already hardened concrete: this is called delayed ettringite. The reaction leading to ettringite formation under these conditions is commonly referred to as Internal Sulfate Reaction (RSI) or Delayed Ettringite Formation (DEF).

Delayed ettringitis can occur several years after the completion of the work. The swelling is then responsible for major disorders in the concrete structure that result visually in the appearance of cracks likely to severely damage said concrete and therefore the structure. The observed cracking can take the form of a multidirectional network and cracks can open up to a few millimeters.

The first known cases of internal sulphate reaction date from 1987. They appeared on prefabricated concrete railway sleepers that had undergone heat treatment. Many countries have been involved, including Finland, Germany, the Czech Republic, Australia, South Africa, the United States or Sweden.

Other cases have appeared in massive pieces of concrete cast in place. This is the case, for example, in the United States, Great Britain and Italy.

The disorders were observed between three and ten years after the construction of the pieces.

This phenomenon was also observed in France from 1997 on bridges whose concrete had been poured into place. They are essentially parts of massive structures (piles, trimmers on piles or abutments, etc.) in contact with water or subjected to high humidity. To date, more than sixty structures are involved, of which about ten are prefabricated elements. Faced with this major problem, various solutions have been envisaged. A first solution consists in preparing cements containing mineral additives such as ground blast furnace slag or fly ash in large proportions. These additions make it possible to dilute the clinker and to limit the risks of internal sulphate reaction and their intensity. However, the workability of the concrete prepared from these cements is less good and their technical performance is weakened. Indeed, grip problems are regularly encountered, the setting time being too long and the speed of rise in resistance being too slow. Furthermore, the mechanical properties of the concretes thus prepared, such as, for example, compressive strength at young ages, are deteriorated compared to a concrete prepared from a cement without addition. In addition, the concretes thus prepared are more sensitive to freeze / thaw cycles.

The cements thus prepared do not therefore meet the technical specifications required for the construction of civil engineering works and buildings with massive elements in contact with water or subjected to a very humid environment.

A second solution is to use CEM I ES type cement according to the standard NF P 15-319 (hydraulic binders - cements for work in water with high sulfate content - designated by ES). Some cements that meet this standard contain 2.7% C ₃ A (value calculated by the Bogue calculation as defined in the LEA's Chemistry of Concrete and Concrete (4th edition), edited by PC Hewlett, p.154). and 2.25% of $. However, the use of these cements did not make it possible to prevent the formation of delayed ettringite due to internal sulphate reactions in the concretes thus prepared.

On the other hand, the use of these cements does not sufficiently limit the external sulphate attacks, that is to say the contributions of sulphate by liquids and / or gases infiltrating the concrete and also leading to the formation delayed ettringitis.

Similar problems exist for grouts and mortars prepared from cements existing at the date of the invention.

It remains therefore necessary to provide a cement that allows the preparation of a concrete, a grout or a mortar, resistant to internal sulphate reactions and external sulphate attacks, while maintaining technical and mechanical characteristics, particularly the setting time and resistance to short times, which allow their use for the construction of civil engineering works, buildings and for the manufacture of prefabricated elements.

The patent application FR 2357500 describes cements for the preparation of concretes resistant to most corrosive media, particularly concentrated solutions of nitrate and sulfate. Since the corrosion resistance caused by concentrated solutions of sulphate can not be confused with resistance to internal sulphate reactions and external sulphate attacks, this patent application does not deal with the same problem as that at the origin of the present invention. . In addition, this patent application teaches that it is essential for good resistance to sulphate attack that the cements contain more than 10% silica fume. However, the use of such amounts of silica requires the addition of a large amount of water to prepare the concrete, grout or mortar, which results in high consistencies of said concrete, grout or mortar, requiring a strong adjuvantation (superplasticizer). On the other hand, silica fume is an expensive product.

Thus, at the date of the present invention, there is still a need for cements for the preparation of concretes, grouts or mortars with mechanical and technical performance compatible with their use for the construction of engineering structures. buildings, and for the manufacture of prefabricated elements, while strongly limiting internal sulphate reactions and external sulphate attacks.

However, against all odds, it has now been found that the use of cements containing 2% or less of C ₃ A, less than 2% of $ and 10% or less of silica fume for the preparation of a concrete, but also a slurry or a mortar, allowed to strongly limit the internal sulphate reactions as well as the external sulphate attacks, while maintaining mechanical and technical performances, in particular the setting time and the resistance to the short times, which allow their use for the realization of works of art of civil engineering, buildings and for the manufacture of prefabricated elements. Thus, the present invention relates to a cement comprising:

from 90% to 100% of a clinker containing

• from 50% to 80% of C ₃ S;

• from 4% to 40% C ₂ S;

· From 0% to 20% of C ₄ AF; and

• from 0% to 2% of C ₃ A;

0%) to 10%) of silica fume; and

- less than 2% of $;

excluding cements including:

- 90% clinker containing

• 55% of C ₃ S;

• 20% C ₂ S;

• 15.2% of C ₄ AF; and

1.6% of C ₃ A;

- and 10%) of silica fume.

The cement according to the present invention allows the preparation of a concrete, but also a grout or a mortar, having mechanical and technical performances, in particular a setting time and a resistance to short times, which allow their use for the construction of civil engineering works, buildings and for the manufacture of prefabricated elements, while strongly limiting the internal sulphate reactions and external sulphate attacks.

In the context of the present invention, the following notations are adopted to designate the mineralogical components of cement:

C represents CaO;

- A represents A1 ₂ 0 ₃ ;

- F represents Fe ₂ O ₃ ;

S represents Si0 ₂ ; and

- $ represents S0 ₃ .

Thus, for example, the alumino ferrite calcium phase of a composition corresponding to the general formula C ₄ AF is actually a (CaO) ₄ (Al ₂ O ₃ ) (Fe ₂ O ₃ ) phase. In addition, in the context of the present invention, the proportions expressed in% correspond to percentages by weight relative to the total weight of the considered entity (cement, concrete, grout or mortar). In the context of the present invention, the phase contents correspond to phase contents measured by the X-ray diffraction analysis associated with the Rietveld calculation method (A Profile Processing Method for Nuclear and Magnetic Structures, HM Rietveld, J. Appl, Cryst (1969) and Advances in Quantitative XRD Analysis for Clinker, Cements, and Cementitious Additions, G. Walenta and T. Fullmann, International Center for Diffraction Data, 2004, Advances in X-ray Analysis, Volume 47). .

The levels thus determined differ from the levels calculated according to the Bug calculation method (as defined in the LEA 'Chemistry of Concrete and Concrete (4th Edition), edited by PC Hewlett, p.154) which does not take into account possible minor elements present in the phases and modifications that these elements may introduce. On the contrary, the X-ray diffraction analysis associated with the Rietveld calculation method makes it possible to measure the phase contents actually present in a clinker or a cement taking into account the modifications and the changes of crystalline phases. The present invention therefore relates to a cement comprising less than 2% of $. Preferably, the present invention relates to a cement as described above comprising less than 1.5% of $, more preferably less than 1% of $.

The cement according to the present invention comprises a clinker as defined above. Preferably, the present invention relates to a cement as described above comprising a clinker whose following characteristics are chosen alone or in combination:

the clinker comprises less than 2% of C ₃ A, preferably of 0% to 1.5% of C ₃ A, most preferably 0% to 1% of C ₃ A; and or

the clinker comprises from 65% to 80% of C ₃ S.

The subject of the present invention is a cement comprising from 90% to 100% of a clinker as defined above, and from 0% to 10% of silica fume. Preferably, the subject of the present invention is a cement as described above comprising less than 10% silica fume, more preferably from 0% to 5% silica fume, preferably still from 0% to 2% silica fume. Most preferably, the present invention relates to a cement as described above without silica fume.

In addition to the foregoing components, the cement according to the present invention may also contain gypsum to adjust the content of $, it being understood that it must remain less than 2%.

The cement according to the present invention may be prepared by any method known to those skilled in the art. In particular, the cement according to the present invention can be prepared by a process comprising the following steps:

crushing of raw materials;

grinding to obtain raw flour;

cooking up to 1450 ° C;

- quenching;

- grinding ;

possible addition during or after grinding of secondary constituents such as silica fume;

possible addition of gypsum, anhydrite or plaster or a mixture thereof. The cement according to the present invention can be prepared from different raw materials such as limestone, clays and marls, iron oxide, siliceous sand and bauxite.

Although the cement according to the present invention is particularly indicated in the preparation of concretes, it can also be used to prepare grouts or mortars. Thus, the present invention also relates to a concrete, a grout or a mortar comprising a cement as described above. Preferably, the present invention relates to a concrete comprising a cement as described above. The present invention is illustrated in a nonlimiting manner by the following examples. Example 1 - Cement 1 according to the invention

A CEM I 52, 5N type cement having the composition reported in the following Table 1 was manufactured:

Table 1

The loss on ignition (975 ° C) is 1%. The cement thus prepared contains about 1% of $.

On the other hand, the phasic composition of this cement is as follows (values measured by the X-ray diffraction analysis associated with the Rietveld calculation method):

- C ₃ S: 72%;

- C ₂ S: 11%;

- C ₄ AF: 13%; and

- C ₃ A: 0.9%. The mechanical characteristics of the cement thus prepared have been measured and are reported in Table 2 below:

(*) Rc: compressive strength according to standard NF EN 196-1

Table 2

The heat of hydration of the cement of the invention is limited, which regulates heating during the setting of the concrete prepared from this cement.

In addition, the setting time and the compressive strengths of the concrete prepared from this cement meet the requirements for the construction of civil engineering structures, buildings and for the manufacture of prefabricated elements. Example 2 - Cement 2 according to the invention

A CEM I 52, 5N type cement having the composition reported in the following Table 3 was manufactured:

Table 3

The cement thus prepared contains about 0.9% of $ and 4% of silica fume. On the other hand, the phasic composition of this cement is as follows (values measured by the X-ray diffraction analysis associated with the Rietveld calculation method):

- C ₃ S: 72%;

- C ₂ S: 12%;

- C ₄ AF: 14%; and

- C ₃ A: 0.8%. The mechanical characteristics of the cement thus prepared have been measured and are reported in Table 4 below:

(*) Rc: compressive strength according to standard NF EN 196-1

Table 4

In addition, the setting time and the compressive strengths of the concrete prepared from this cement meet the requirements for the construction of civil engineering structures, buildings and for the manufacture of prefabricated elements. Example 3 - Concretes prepared from cements according to the invention

A first concrete and a second concrete are prepared respectively from the cements of Example 1 (concrete 1) and Example 2 (concrete 2). The final composition of these concretes is as follows:

Table 5

The resistance of these concretes (concrete 1 and concrete 2) to the internal sulphate reactions is studied according to the LPC method n ° 66 in comparison with a concrete prepared from a cement CEM I 52.5N PM ES classic and in conformity with the norm NF P 15-319 (concrete 3). The purpose of this performance test is to determine the ability of a concrete to withstand the internal sulphate reaction; this is a swelling test. After fabrication, the concrete specimens undergo heat treatment at 80 ° C to simulate heating. Then the concrete is exposed to two cycles of humidification-drying (Drying for 7 days in the chamber at 38 ° C and RH <30% then immersion for 7 days in water network 20 +/- 2 ° VS). The test pieces are then stored in a water tank at 20 ° C. and their longitudinal deformation is measured regularly. The observed results are reported Figure 1.

Criterion 1 according to LPC Method No. 66 corresponds to:

- the average longitudinal deformation of 3 test specimens is less than 0,04% and no individual value exceeds 0,06% at the expiry of 12 months;

and the monthly variation of the mean longitudinal deformation of 3 test pieces measured from the 3rd month is less than 0.004%. Criterion 2 according to LPC Method No. 66 corresponds to:

- the individual longitudinal deformation of the 3 test pieces is between 0.04% and 0.07% o at the expiry of 12 months. It is then necessary to prolong the test until the 15th month;

and the monthly change in mean longitudinal deformation of 3 test pieces measured from the 12th month is less than 0.004% and the cumulative variation between the 12th and 15th month is less than 0.006%.

In contrast to concrete prepared from a CEM I 52.5N PM ES type cement, the concretes of the invention do not develop internal sulphate reactions.

Thus, the concrete 1 meets the criterion 1 of the LPC method No. 66 and the concrete 2 meets the criterion 2 of the LPC method No. 66, while the concrete prepared from the cement type CEM I 52.5N PM ES does not meets none of these criteria.

Example 4 Mortars Prepared from Cements According to the Invention

A first mortar and a second mortar are prepared by mixing respectively the cements of Example 1 (mortar 1) and of Example 2 (mortar 2) with sand, water and an addition of calcium sulphate so that the $ content of the mortar is 7%.

The resistance of these mortars (mortar 1 and mortar 2) to external sulphate attacks is measured by a test conducted according to ASTM C 452 in comparison with a mortar prepared from a conventional CEM I 52.5N PM ES cement and in accordance with standard NF P 15-319 (mortar 3). This test makes it possible to determine the expansion of a mortar by measuring the longitudinal deformation of a specimen.

The results are reported Figure 2.

At 14 days, the mortars prepared from the cements according to the invention did not reach the limit fixed by Γ ASTM. In addition, at 430 days, the swelling stabilized at 0.025% for the mortar 1 and at 0.045% for the mortar 2 while the swelling of the mortar prepared from cement CEM I 52.5N PM ES always increases.

Unlike the mortar prepared from a CEM I 52.5N PM ES cement, the mortars prepared from the cements of the invention are very insensitive to external sulphate attacks.

Claims

1. Cement comprising:

from 90% to 100% of a clinker containing

• from 50% to 80% of C ₃ S;

• from 4% to 40% C ₂ S;

• from 0% to 20% of C ₄ AF; and

• from 0% to 2% of C ₃ A;

0%) to 10%) of silica fume; and

- less than 2% of $;

excluding cements including:

- 90% clinker containing

• 55% of C ₃ S;

· 20% C ₂ S;

• 15.2% of C ₄ AF; and

1.6% of C ₃ A;

- and 10%) of silica fume.

2. Cement according to claim 1, characterized in that it comprises less than 1.5% of $.

3. Cement according to claim 2, characterized in that it comprises less than 1% of $.

4. Cement according to any one of claims 1 to 3, characterized in that the clinker comprises 0%> to 1.5% C ₃ A.

5. Cement according to claim 4, characterized in that the clinker comprises from 0% to 1% C ₃ A.

6. Cement according to any one of claims 1 to 5, characterized in that the clinker comprises 65%> to 80%> of C ₃ S.

7. Cement according to any one of claims 1 to 6, characterized in that it comprises from 0% to 5% of silica fume.

8. Cement according to claim 7, characterized in that it comprises from 0% to 2% silica fume.

9. Cement according to any one of claims 1 to 8, characterized in that it also comprises gypsum.

10. Concrete comprising a cement according to any one of claims 1 to 9.

11. Grout comprising a cement according to any one of claims 1 to 9.

12. Mortar comprising a cement according to any one of claims 1 to 9.